Synthetic flooring with area elastic properties

ABSTRACT

In accordance with a representative embodiment broadly described herein, the present invention provides for a resilient athletic surface. The surface includes a resilient base layer, an intermediate layer, and a clear polymer wear layer. The athletic surface is configured such that it is area elastic. In one embodiment, the athletic surface can have a visual appearance of being a wood surface or varnished wood surface.

This application claims the benefit of U.S. Provisional Patent Application No. 61/565,378, filed Nov. 30, 2011, and which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to synthetic flooring, and more specifically to area elastic synthetic flooring for use in athletic and related activities.

BACKGROUND OF THE INVENTION AND RELATED ART

Many types of athletic and sports flooring products have been designed and produced in order to satisfy the requirements of not only professional and collegiate sports competition, but also for the practice of physical and sporting activities of lower levels such as primary and secondary schools, community centers, or private gyms. The technical criteria of sports floors vary depending on the intended use, but that brings with it financial and economic constraints. The wide range of use for athletic flooring surfaces demands floor areas ranging from about 100 square feet to about 100,000 square feet and thus the choice and design of sports floors in relation to their criteria and conditions of use have considerable financial consequences. With this in mind, there are several different types of flooring that are currently available including both point elastic floors and area elastic floors.

Point elastic floors are made of synthetic materials produced in one or more layers and typically come in the form of strips rolled out to the desired length that are placed directly onto the receiving concrete base. In point elastic flooring the weight of the user is spread over an area only slightly greater than the surface area of the user's foot. Thus, the impact zone has a size that is only a few centimeters (3 to 5 cm) larger than the area contacted by the foot. This type of covering is satisfactory in relation to its low cost and its high of durability (wear, maintenance, resistance to impacts); however, the sporting properties are limited due to the thickness-flexibility compromise of the floor which prevents the cushioning layer from being increased without experiencing problems of stability of support. Additionally, the synthetic nature and look of most point elastic floors typically does not provide the aesthetically pleasing look of traditional wood floors.

Area elastic floors are typically made of wood-based materials and provide desirable performance characteristics and aesthetically pleasing looks. In area elastic floors the load of the user (e.g. athlete) is spread over an area much greater than the contact area of the user's foot (approximately 50 cm around the foot). One common example of an area elastic floor is a wood. Traditionally, wood flooring starts from the concrete base followed by a first covering made of polyurethane foam of a certain thickness onto which are placed two superposed tiers of wood panels arranged in staggered pattern, with a finish covering. This type of floor is often used in facilities where basketball is played, particularly competitive basketball, due to the sporting properties provided by these floors. Unfortunately, the investment cost for most area elastic sports floors of this type is extremely high. The fitment and installation time is long due to the disposition of the two tiers of wood panels and the difficulties of correctly filling the whole surface area of the facility in question. In addition, and from the technical point of view, traditional area elastic wood floors can suffer from certain drawbacks or disadvantages including sensitivity and damage due to humidity and/or temperature fluctuations, high costs of maintenance, and the requirement for regular revarnishing. Due to the high costs of installation and maintenance, area elastic floors, such as described above, are typically used only in high level sports facilities and gymnasia for particular sporting activities such as basketball, handball and volleyball.

With all of this in mind, research continues into flooring compositions and systems than can provide the durability and costs associated with typical synthetic flooring while providing the aesthetics and area-elastic performance of traditional wood flooring systems.

SUMMARY OF THE INVENTION

In accordance with a representative embodiment broadly described herein, the present invention provides for a resilient athletic surface. The surface includes a resilient base layer, an intermediate vinyl layer, and a clear polymer wear layer. The athletic surface is configured such that it is area elastic. In one embodiment, the athletic surface has a visual appearance of being a wooden surface.

BRIEF DESCRIPTION OF THE DRAWINGS

Features and advantages of the present invention will be apparent from the detailed description that follows, and when taken in conjunction with the accompanying drawing together illustrate, by way of example, features of the invention. It will be readily appreciated that these drawings merely depict representative embodiments of the present invention and are not to be considered limiting of its scope, and that the components of the invention, as generally described and illustrated in the figures herein, could be arranged and designed in a variety of different configurations. Nonetheless, the present invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:

FIG. 1 is a side cross-sectional view of one embodiment of the athletic surface of the present invention.

Reference will now be made to additional embodiments and specific language will be used herein to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Furthermore, the following detailed description and representative embodiments of the invention will be best understood with reference to the accompanying drawing, wherein the elements and features of the embodiments are designated by numerals throughout.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, it should be understood that other embodiments may be realized and that various changes to the invention may be made without departing from the spirit and scope of the present invention. Thus, the following more detailed description of the embodiments of the present invention is not intended to limit the scope of the invention, as claimed, but is presented for purposes of illustration only and not limitation to describe the features and characteristics of the present invention, to set forth the best mode of operation of the invention, and to sufficiently enable one skilled in the art to practice the invention. Accordingly, the scope of the present invention is to be defined solely by the appended claims.

Definitions

It should be noted that, the singular forms “a,” “an,” and, “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a substrate” includes reference to one or more of such substrates, and reference to “the substrate” includes reference to one or more of such substrates.

As used herein, the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, an object that is “substantially” enclosed would mean that the object is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context. However, generally speaking the nearness of completion will be so as to have the same overall result as if absolute and total completion were obtained. The use of “substantially” is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result.

As used herein, “tensile strength” refers to the standard definition of the term and is determined using the testing methodology prescribed in ASTM D412.

As used herein, “hardness” when used in connection with the polymer wear coat of the athletic surface of the present invention refers to the polymer wear coat's ability to resist to permanent indentation. Unless otherwise stated, the hardness of the wear coat is determined using the testing methodology prescribed in ASTM D2240.

As used herein, “elongation” refers to the standard definition of the term when used to describe properties of a polymeric material such as the polymer used in the polymer wear layer of the athletic surfaces of the present invention. The elongation value is determined using the testing methodology prescribed in ASTM D412.

As used herein, the term “tear strength” when used in connection with polymer wear layer of the athletic surface of the present invention refers to the ability of the wear layer to resist tearing. The tear strength value is determined used the testing methodology prescribed in ASTM D624.

As used herein, “area elastic” as used to describe athletic surfaces disclosed herein refers to athletic surfaces in which a point force causes deflection over a relatively large area around the point of application of force. Area elastic floors can have shock absorption of at least about 40% to about 75% (using standard shock absorption testing methodology) and vertical deformation of at least about 2.3 mm to about 5.0 mm (based on standard vertical deformation testing methodology).

As used herein, the term “about” is used to provide flexibility to a numerical range endpoint by providing that a given value may be “a little above” or “a little below” the endpoint.

As used herein, a plurality of items, structural elements, compositional elements, and/or materials may be presented in a common list for convenience. However, these lists should be construed as though each member of the list is individually identified as a separate and unique member. Thus, no individual member of such list should be construed as a de facto equivalent of any other member of the same list solely based on their presentation in a common group without indications to the contrary. In addition, various embodiments and example of the present invention are referred to herein along with alternatives for the various components thereof. It is understood that such embodiments, examples, and alternatives are not to be construed as de facto equivalents of one another, but are to be considered as separate and autonomous representations of the present invention.

Concentrations, amounts, levels and other numerical data may be expressed or presented herein in a range format. It is to be understood that such a range format is used merely for convenience and brevity and thus should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. As an illustration, a numerical range of “about 1 to about 5” should be interpreted to include not only the explicitly recited values of about 1 to about 5, but also include individual values and sub-ranges within the indicated range. Thus, included in this numerical range are individual values such as 2, 3, and 4 and sub-ranges such as from 1-3, from 2-4, and from 3-5, etc., as well as 1, 2, 3, 4, and 5, individually. This same principle applies to ranges reciting only one numerical value as a minimum or a maximum. Furthermore, such an interpretation should apply regardless of the breadth of the range or the characteristics being described.

Invention

With the above definitions in mind, the present invention is drawn to a resilient athletic surface. The surface includes a resilient base layer, an intermediate vinyl layer, and a clear polymer wear layer. The athletic surface is configured such that it is area elastic. In one embodiment, the athletic surface has a visual appearance of being a wood surface or varnished wood surface. In contrast to most synthetic flooring surfaces that are typically heat sealed rows, tiles or pieces, the athletic flooring surfaces of the present invention are monolithic area elastic surfaces that can be manufactured on site minimizing or eliminating the need for extensive seeming of jointing.

FIG. 1 shows an exemplary embodiment of an athletic surface of the present invention. Moving from the bottom of the figure, the athletic surface includes a resilient base layer 8 configured to be disposed on a solid substrate material (not shown). The substrate material could be a concrete, asphalt, packed earth, or other generally hard and substantially flat substrate onto which an athletic surface might be applied. The resilient base layer of the embodiment has an intermediate vinyl layer 4 adhered on its upper surface utilizing an adhesive layer 6. The clear polymer wear layer 2 is disposed on the upper surface of the intermediate vinyl layer opposite the resilient base layer.

The resilient base layer of the athletic surface disclosed herein can be made of a variety of manmade and or natural materials so long as they have the requisite resiliency and durability. For example, in one embodiment, the resilient base layer can include rubber and recycled rubber materials, ground foam particles, combinations thereof, and the like. The thickness of the resilient base layer can vary depending on a number of factors including, but not limited to, the type and properties of substrate onto which the athletic surface is intended to be used and the nature of the materials which make up the resilient base layer. In one embodiment, the resilient base layer can have a thickness of about 3 mm to about 15 mm. In another embodiment, the resilient base layer can have a thickness of about 4 mm to about 14 mm. The resilient base layer can also include an anti-microbial compound to inhibit growth of microbial organisms in the athletic surface.

The intermediate layer is disposed on the upper surface of the resilient base layer and can be adhered to the base layer using an adhesive compound. In one embodiment, the adhesive compound can be formulated to have minimal penetration into the resilient base layer while still providing adequate adhesiveness to maintain the intermediate layer in contact with the resilient base layer. It is important that the adhesive compound provide adequate adhesion in order for the flooring to have desirable structural stability. However, excess penetration of the adhesive compound into the resilient pad can diminish the resilient properties of the resilient pad thereby resulting in a less suitable and functional floor. Accordingly, providing an adhesive compound formulated for minimal penetration into the resilient base layer while still providing sufficient adhesion can be important. Non-limiting examples of an adhesive that can be used include water based urethane adhesives such as o-VOC 100% solids urethane adhesives that can be either rolled or spray applied. The intermediate layer can be made of vinyl or other similar materials.

The intermediate layer can be a solid color or can have a print or pattern on its upper surface. In one embodiment, the intermediate layer can have a wood grain print on its upper surface. In another embodiment, the vinyl layer can have one or more painted image or line disposed on its upper surface such that it can be seen through the clear polymer wear coat. The images or game lines are permanent and will not chip, peal, or wear due to their location under the clear polymer wear layer. In one embodiment, the intermediate layer can have a thickness of about 1.8 mm to about 2.4 mm. In another embodiment, the intermediate layer has a thickness of about 1.9 mm to about 2.3 mm.

The clear polymer wear layer of the disclosed athletic surface is generally transparent and can be formed of a single polymer, a copolymer, or combination of polymers. The clarity of the upper wear surface is useful because it allows for the viewing of the print on the intermediate layer thereby allowing the athletic surface to have aesthetically pleasing properties. When the print on the intermediate layer is a wood grain print, the athletic surface can have the appearance of a traditional natural wood athletic floor. The polymer wear layer of the athletic surfaces of the present invention has excellent properties that minimize splitting, tearing, and damage. In fact, the polymer wear layer has sufficient wear and strength properties that it not only functions well as a traditional athletic floor but it can also be used for skating and/or wheel chair use without causing damage to the floor.

Although other clear polymer materials may be used so long as they provide the desired area elastic effect, in one embodiment, the clear polymer wear layer can include a polyuria polymer. In another embodiment, the polymer utilized in the polymer wear layer can have the property that it achieves a hardness of at least about 90 Shore A within about 12 to about 18 hours of application to the intermediate layer. In still another embodiment, the clear polymer wear layer of the athletic surface can have a hardness of at least about 94 Shore A after curing. In yet a further embodiment, the clear polymer wear layer of the athletic surface can have a hardness of at least about 95 Shore A after curing.

In one aspect of the present invention, the clear polymer wear layer of the athletic surface can have an elongation value of at least about 250%. In another embodiment, the clear polymer wear layer can have an elongation value of at least about 300%. In another embodiment, the clear polymer wear layer can have an elongation value of at least about 350%. In still a further embodiment, the clear polymer wear layer can have an elongation value of at least about 400%. In a further aspect of the invention the clear polymer wear layer can have a tear strength of at least about 250 pli. In another embodiment, the clear polymer wear layer can have a tear strength of at least about 300 pli.

In one embodiment, the polymer utilized in the clear polymer wear layer be formulated to cure and achieve the requisite hardness without the need apply thermal heat or UV light. The ability of the polymer used in the polymer wear layer to cure without the need to thermal heat or UV light is particularly beneficial because it allows the athletic surface to be manufactured in the on-site and over large areas.

The polymer used in the polymer wear layer can be formulated to have a cured tensile strength of at least about 1900 psi. In another embodiment, the polymer used in the polymer wear layer can have a tensile strength of at least about 1950 psi. In yet a further embodiment, the polymer used in the polymer wear layer can have a tensile strength of at least about 2000 psi.

The clear polymer wear layer of the athletic surface can have a thickness that is sufficient provide adequate stiffness and rigidity to achieve the desired area elastic effect. In one embodiment, the clear polymer wear layer of the athletic surface can have a thickness of about 1 mm to about 3 mm. In yet another embodiment, the clear polymer wear layer can have a thickness of about 1.3 mm to about 2.5 mm.

While the forgoing examples are illustrative of the principles of the present invention in one or more particular applications, it will be apparent to those of ordinary skill in the art that numerous modifications in form, usage and details of implementation can be made without the exercise of inventive faculty, and without departing from the principles and concepts of the invention. Accordingly, it is not intended that the invention be limited, except as by the claims set forth below. 

What is claimed and desired to be secured by Letters Patent is:
 1. A resilient athletic surface, comprising: a resilient base layer; an intermediate layer; and a clear polymer wear layer; wherein the athletic surface has area elastic properties.
 2. The athletic surface of claim 1, wherein the resilient base layer comprises recycled rubber particles.
 3. The athletic surface of claim 1, wherein the resilient base layer comprises foam particles.
 4. The athletic surface of claim 1, wherein the resilient base layer has a thickness of about 3 mm to about 15 mm.
 5. The athletic surface of claim 1, wherein the clear polymer wear layer comprises a polyuria polymer.
 6. The athletic surface of claim 5, wherein the polyuria polymer achieves a hardness of at least about 90 Shore A within about 12 to about 18 hours of application to the intermediate layer.
 7. The athletic surface of claim 5, wherein the polyuria polymer has a tensile strength of at least about 1900 psi.
 8. The athletic surface of claim 5, wherein the polyuria polymer has a tensile strength of at least about 1950 psi.
 9. The athletic surface of claim 5, wherein the polyuria polymer has a tensile strength of at least about 2000 psi.
 10. The athletic surface of claim 1, wherein the clear polymer wear layer has a thickness of about 1 mm to about 3 mm.
 11. The athletic surface of claim 1, wherein the clear polymer wear layer has a thickness of about 1.3 mm to about 2.5 mm.
 12. The athletic surface of claim 1, wherein the clear polymer wear layer has a hardness of at least 94 Shore A.
 13. The athletic surface of claim 1, wherein the clear polymer wear layer has a hardness of at least about 95 Shore A.
 14. The athletic surface of claim 1, wherein the clear polymer wear layer has a elongation value of at least about 250%.
 15. The athletic surface of claim 1, wherein the clear polymer wear layer has an elongation value of at least about 300%.
 16. The athletic surface of claim 1, wherein the clear polymer wear layer has an elongation value of at least about 350%.
 17. The athletic surface of claim 1, wherein the clear polymer wear layer has an elongation value of at least about 400%.
 18. The athletic surface of claim 1, wherein the clear polymer wear layer has a tear strength of at least about 250 pli.
 19. The athletic surface of claim 1, wherein the clear polymer wear layer has a tear strength of at least about 300 pli.
 20. The athletic surface of claim 1, wherein the intermediate layer is a vinyl layer.
 21. The athletic surface of claim 1, wherein the intermediate layer has a wood grain print on a surface thereof.
 22. The athletic surface of claim 1, further comprising painted images disposed between the intermediate layer and the polymer wear coat.
 23. The athletic surface of claim 1, wherein the intermediate layer has a thickness of about 1.8 mm to about 2.4 mm.
 24. The athletic surface of claim 1, wherein the intermediate layer has a thickness of about 1.9 mm to about 2.3 mm.
 25. The athletic surface of claim 1, wherein the intermediate layer has a wood-like appearance. 